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Advanced Coatings for Corrosion Protection in Extreme Environments

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A special issue of Coatings (ISSN 2079-6412).

Deadline for manuscript submissions: closed (30 October 2018) | Viewed by 65314

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Prof. Dr. Homero Castaneda

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Materials Science and Engineering, Director of the National Corrosion and Materials Reliability Center, Texas A&M University, College Station, TX, USA
Interests: degradation of materials, including passivation and localized corrosion of metals and alloys (CRA, shape memory alloys, high-entropy alloys); additive manufacturing of alloys, polymers, and oxides; corrosion inhibition; multifunctional and self-healing coatings; multiscale-electrochemical measurements; pipeline integrity management, including corrosion defect assessment by numerical modeling, and data driven corrosion assessment (machine learning, neural network)
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Velumani Subramaniam

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Department of Electrical Engineering (SEES), Centro de Investigación y de Estudios Avanzados del I.P.N.(CINVESTAV), Av. Instituto Politécnico Nacional # 2508, Col. San Pedro Zacatenco, 07360, México D.F., Mexico
Interests: protective coatings; microscopic analysis; DFT calculations and modeling

Special Issue Information

Dear Colleagues,

Recent theoretical and experimental developments in multifunctional coatings as single or multilayers covering metallic substrates are among the most highly-exploited research systems in the field of corrosion science and engineering. Spurred primarily by durability in demanding environmental conditions required by current applications ranging from aerospace, medical, automotive and chemical industries to oil and gas technologies. Driven by the current state of knowledge of corrosion prevention mechanisms, the need to maintain structural material integrity and reliability assets under harsh environments, and a renewed impetus towards durability of new nanostructured coating systems, have seen a huge demand on experimental, theoretical and modeling activities.

The manufacture, design and test of high-performance nanostructured materials that are either electroactive (e.g., metals, graphene, carbon nanotubes, conductive polymers, etc.) or are capable of serving as physical protection layers (organic polymers, composites materials, ceramic materials, etc.) or combination provides unprecedented functionality and opportunities for multifunctional coatings protecting the metallic structures (steels, stainless steels, aluminum, and magnesium).

This scope of this Special Issue will serve as a forum for papers in the following concepts:

Theoretical and experimental research, knowledge and new ideas in corrosion protective and preventive coatings mechanisms.
Recent developments in multi-functional organic, inorganic, hybrid coatings
Coatings produced by different processes, including but not limit to additive manufacturing processes, thermal spray, laser and plasma processing, CVD, plating, etc.
Experimental and processing high-performance coatings with exposure to high temperatures, high stress, and other extreme environment applications.
Understanding the degradation mechanisms of coatings through friction, wear or other dynamic loading condition and corrosion.
The latest development of test methods considering the interplay between mechanical, chemical, and electrochemical interactions and the ability to predict performance and/or reliability. Emphasis on valid, accelerated performance tests and the relation between test technique and field performance data.
Computer modeling, simulation to predict coating properties, performance, durability and reliability in service environments.

Prof. Dr. Homero Castaneda
Prof. Dr. Velumani Subramaniam
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

Protective corrosion coatings
Extreme environments
Performance modeling
Reliability coatings
Damage evolution modeling of coatings

Published Papers (14 papers)

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Research

18 pages, 31754 KiB

Open AccessArticle

The Evaluation on Corrosion Resistance and Dross Formation of Zn–23 wt % Al–0.3 wt % Si–x wt % Mg Alloy

by Wangjun Peng, Guangxin Wu, Rui Lu, Quanyong Lian and Jieyu Zhang

Coatings 2019, 9(3), 199; https://doi.org/10.3390/coatings9030199 - 19 Mar 2019

Cited by 2 | Viewed by 4404

Abstract

A comparative study of the corrosive resistance and dross formation of 55Al–Zn–1.6Si (wt %) (55AZS) and 23Al–Zn–0.3Si–xMg (wt %) (23AZS–xMg, x = 0, 1.5, 3) alloys are performed using immersion corrosion and dross formation test, respectively. The result of immersion corrosion testing shows that corrosive rate of the 23AZS alloy is lower than that of 55AZS alloy in the latter stage of immersion and 23AZS–1.5Mg alloy shows the optimal corrosive resistance compared to other alloys relatively. The result of dross formation test shows that the number of bottom dross particle formed in 23AZS–xMg (x = 0, 1.5, 3) alloy is less than that in 55AZS alloy. Moreover, the thermodynamic calculation is performed to reveal the solubility of Fe in the alloys, the result shows the solubility of Fe reduces as a decrease of Al content in the alloy, and the number of dross particle (Fe₄Al₁₃ and τ₆ (Al₉Fe₂Si₂) phase) generated in 23AZS alloy is more than that in 55AZS alloy. In general, 23AZS–1.5Mg alloy has an advantage of less dross and a certain corrosion resistance and it is expected to be applied for the hot stamping process of coating. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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18 pages, 8793 KiB

Open AccessArticle

Corrosion Behavior Evaluation of Coated Steel Using Fiber Bragg Grating Sensors

by Fodan Deng, Ying Huang and Fardad Azarmi

Coatings 2019, 9(1), 55; https://doi.org/10.3390/coatings9010055 - 17 Jan 2019

Cited by 13 | Viewed by 4310

Abstract

Coatings, either soft or hard, are commonly used to protect steel against corrosion for longer service life. With coatings, assessing the corrosion behavior and status of the substrate is challenging without destructive analysis. In this paper, fiber Bragg (FBG) grating sensors were proposed to nondestructively evaluate the corrosion behavior of steel coated with two popular coatings, including the polymeric and wire arc sprayed Al-Zn coating. Laboratory accelerated corrosion tests demonstrated that the embedded FBG sensors inside both the soft and hard coatings can effectively quantify the corrosion rate, monitor the corrosion progress, and detect the coating damages and crack propagation of coated steel in real time. The laboratory electrochemical corrosion test on the wire arc sprayed Al-Zn coating validated the proposed embedded FBG sensor method with a good agreement in comparison. The proposed sensing platform provides an alternative nondestructive real-time corrosion assessment approach for coated steel in the field. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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10 pages, 7427 KiB

Open AccessArticle

One-Step Potentiostatic Deposition of Micro-Particles on Al Alloy as Superhydrophobic Surface for Enhanced Corrosion Resistance by Reducing Interfacial Interactions

by Tian Shi, Xuewu Li, Qiaoxin Zhang and Ben Li

Coatings 2018, 8(11), 392; https://doi.org/10.3390/coatings8110392 - 05 Nov 2018

Cited by 3 | Viewed by 3181

Abstract

Corrosion failure is a thorny problem that restricts the application of Al alloys. As a new technique for functional realization, hydrophobic preparation offers an efficient approach to solve corrosion problem. This work has developed a facile and low-cost method to endow Al alloy with enhanced water-repellent and anticorrosion abilities. The micro-particles have been firstly prepared by one-step deposition process. Furthermore, wetting and electrochemical behaviors of as-prepared structures have been investigated after silicone modification. Results show that the fabricated surface possesses excellent superhydrophobicity with a water contact angle (CA) of 154.7° and a sliding angle (SA) of 6.7°. Meanwhile, the resultant surface is proved with enhanced corrosion resistance by reducing interfacial interactions with seawater, owing to newly-generated solid-air-liquid interfaces. This work sheds positive insights into extending applications of Al alloys, especially in oceaneering fields. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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13 pages, 6479 KiB

Open AccessArticle

Isothermal Oxidation Behavior of Zr-Y Coating on γ-TiAl by Double Glow Plasma Surface Metal Alloying Technique

by Feng Ding, Pingze Zhang, Dongbo Wei, Xiaohu Chen, Shiyuan Wang, Zhangzhong Wang and Yimin Zhu

Coatings 2018, 8(10), 361; https://doi.org/10.3390/coatings8100361 - 12 Oct 2018

Cited by 3 | Viewed by 2880

Abstract

Oxidation resistance of Zr-Y coating on γ-TiAl alloy prepared by a double-glow plasma surface alloying technique was investigated in static air at 750 °C, 800 °C and 850 °C for 100 h. A pure Zr coating was also prepared for comparison. Addition of Y improved high-temperature oxidation resistance of the alloying coating because of its refining effect and inhibition of cationic diffusion. Oxidation kinetic curves indicated that the high-temperature oxidation resistance of the Zr-Y coating was about eight times higher than that of the bare substrate and about 3 times higher than that of pure Zr coating. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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11 pages, 3855 KiB

Open AccessArticle

Destructive Effect of Water Vapour on an In Situ Diffusion Barrier Layer within an Aluminide Coating on IN738 Alloy

by Chao Li, Peng Song, Kunlun Chen, Xuan He, Xiao Yu and Jiansheng Lu

Coatings 2018, 8(10), 332; https://doi.org/10.3390/coatings8100332 - 21 Sep 2018

Cited by 5 | Viewed by 3582

Abstract

High-temperature interdiffusion within a hot-dipped aluminide (Al-10 wt.% Si) coating on an IN738 superalloy was investigated at 1050 °C in air and in air plus water vapour. The resulting morphology of in situ diffusion barrier layer (DBL) within the aluminide coating is affected by oxidizing atmospheres; DBL can effectively retard the interdiffusion of aluminium within the coating. The location of the in situ DBL is governed by the partial pressure of oxygen at different depths from the oxide scales in both atmospheres. Meanwhile, the diffusion fluxes of different elements led to DBLs with different morphologies in the aluminide coating on the Ni-based alloy. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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11 pages, 3817 KiB

Open AccessArticle

Corrosion Protection of N80 Steel in Hydrochloric Acid Medium Using Mixed C₁₅H₁₅NO and Na₂WO₄ Inhibitors

by Jun Hu, Tiantian Wang, Zhen Wang, Liping Wei, Jianbo Zhu, Maosheng Zheng and Zhong Chen

Coatings 2018, 8(9), 315; https://doi.org/10.3390/coatings8090315 - 06 Sep 2018

Cited by 12 | Viewed by 4403

Abstract

A novel inhibitor based on mixed Mannich base (C₁₅H₁₅NO) and Na₂WO₄ was developed for the corrosion prevention of N80 steel in hydrochloric acid solution. Infra-red spectrum, electrochemical measurements, X-ray Photoelectron Spectroscopy, and Scanning Electron Microscopy were used to understand the inhibition efficiency and mechanism. The results showed that the mixed inhibitors reduced the corrosion current density and increased the interface resistance. The inhibition efficiency is the highest when the ratio of C₁₅H₁₅NO to Na₂WO₄ is 1:1 in the mixture. Observed from the surfaces, the number of pits and small cracks was reduced on the surface in the presence of the optimized inhibitors. The inhibition film can successfully hinder the chloride ions from reaching the bulk steel. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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12 pages, 7690 KiB

Open AccessEditor’s ChoiceArticle

Corrosion Behavior of Fe/Zr Composite Coating on ZK60 Mg Alloy by Ion Implantation and Deposition

by Yang Zheng, Libin Zang, Yanze Bi, Yan Li and Yong Chen

Coatings 2018, 8(8), 261; https://doi.org/10.3390/coatings8080261 - 26 Jul 2018

Cited by 18 | Viewed by 4060

Abstract

The Fe/Zr composite coating was prepared by duplex Fe/Zr ion implantation and deposition to modify the microstructure and corrosion behavior of Mg-5.5 Zn-0.6 Zr (in wt.%, ZK60) alloy. The surface and interface characteristics were investigated using X-ray diffraction (XRD), atomic force microscope (AFM) and scanning electron microscopy (SEM). The results showed that the Fe/Zr composite coating exhibited a bi-layer microstructure of outer Fe-rich layer and inner Zr-rich layer. Multi-phases of α-Fe, ZrO₀.₃₅ and Zr₆Fe₃O were formed on the modified surface. The electrochemical measurements and immersion tests revealed an improvement of corrosion behavior for the surface-modified sample due to the protective effect of Fe/Zr composite coating. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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14 pages, 3623 KiB

Open AccessArticle

Development and Characterization of Anticorrosion and Antifriction Properties for High Performance Polyurethane/Graphene Composite Coatings

by Pei-Ying Tsai, Tzu-En Chen and Yueh-Lien Lee

Coatings 2018, 8(7), 250; https://doi.org/10.3390/coatings8070250 - 16 Jul 2018

Cited by 36 | Viewed by 5499

Abstract

This work contributes to the development and characterization of the corrosion resistance and antifriction properties of high performance polyurethane (PU)/graphene (Gr) composite coating. In this study, PU composite coatings containing 0, 2, 4 and 8 wt.% of Gr were prepared and evaluated using various corrosion and mechanical tests, namely electrochemical impedance spectroscopy, salt spray tests, cross-cut tape tests and dynamic mechanical analysis. Antifriction properties of the coatings were evaluated using a tribometer with a ball-on-disc mode at room temperature. The corrosion resistance and adhesion property of the PU coatings were found to be enhanced by adding 4 and 8 wt.% of Gr. The coefficient of friction revealed that the antifriction properties of the PU/Gr composite coatings were 61% lower than those of the conventional coating when the Gr content was increased to 8 wt.%. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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17 pages, 3145 KiB

Open AccessArticle

Evolution of Calcareous Deposits and Passive Film on 304 Stainless Steel with Cathodic Polarization in Sea Water

by Tianxiang Sun, Guosheng Huang, Ping Lv, Likun Xu and Li Ma

Coatings 2018, 8(5), 194; https://doi.org/10.3390/coatings8050194 - 21 May 2018

Cited by 6 | Viewed by 4695

Abstract

The change of protective current density, the formation and growth of calcareous deposits, and the evolution of passive film on 304 stainless steel (SS) were investigated at different potentials of cathodic polarization in sea water. Potentiostatic polarization, electrochemical impedance spectroscopy (EIS), and surface analysis techniques of scanning electron microscopy (SEM), energy dispersive X-ray (EDX) microanalysis and X-ray diffraction (XRD) were used to characterize the surface conditions. It was found that the protective current density was smaller for keeping polarization at −0.80 V (vs. saturated calomel electrode (SCE), same as below) than that at −0.65 V. The calcareous deposits could not be formed on 304 SS with polarization at −0.50 V while it was well protected. The formation rate, the morphology, and the constituent of the calcareous deposits depended on the applied potential. The resistance of passive film on 304 SS decreased at the first stage and then increased when polarized at −0.80 V and −0.65 V, which was related to the reduction and the repair of passive film. For the stainless steel polarized at −0.50 V, the film resistance increased with polarization time, indicating that the growth of oxide film was promoted. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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10 pages, 4817 KiB

Open AccessArticle

Effect of Annealing Treatment on Microstructure and Properties of Cr-Coatings Deposited on AISI 5140 Steel by Brush-Plating

by Jianjun Hu, Jie Jiang, Hui Li, Xian Yang, Hongbin Xu, Yan Jin, Chaoping Ma, Qingshan Dong and Ning Guo

Coatings 2018, 8(5), 193; https://doi.org/10.3390/coatings8050193 - 21 May 2018

Cited by 12 | Viewed by 6953

Abstract

Cr-coating was deposited on AISI 5140 steel by electro brush-plating, followed by annealing treatment at different temperatures, from 300 to 1100 °C. The microstructure evolution of the Cr-coating was characterized by backscattered electron imaging (BSEI) and energy dispersive spectrometry (EDS). The results show that the brush-plated sample has a nodular shaped microstructure, which is very stable at 300 °C of annealing. At 500 °C of annealing, the constitution of the microstructure changes from nodules to grains. As the annealing temperature further increases, the grains grow significantly. When the temperature reaches 1100 °C, a Cr-Fe solid-solution layer is formed within the original pure Cr-coatings. With increasing annealing temperature, the number of micro-cracks in the coating increases first and then decreases, reaching a maximum at 500 °C. The hardness and wear-resistance of the coating are improved when the annealing temperature increases to 1100 °C, owing to the decrease of micro-cracks that formed during brush-plating. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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16 pages, 3605 KiB

Open AccessArticle

Electrodeposition of a Pd-Ni/TiO₂ Composite Coating on 316L SS and Its Corrosion Behavior in Hot Sulfuric Acid Solution

by Zhiheng Zhang, Junlei Tang, Yingying Wang, Hu Wang, Bernard Normand and Yu Zuo

Coatings 2018, 8(5), 182; https://doi.org/10.3390/coatings8050182 - 11 May 2018

Cited by 9 | Viewed by 5098

Abstract

Pd-Ni/TiO₂ composite coatings were elaborated on 316L stainless steel by an electrodeposition method. The specimens were obtained from an electrolytic bath that contained various contents (5, 10, and 15 g L⁻¹) of nanosized TiO₂ particles. X-ray diffraction (XRD) characterization showed that increasing the TiO₂ content in the coatings can decrease the crystal grain size. The surface morphology and chemical composition of the composite coatings were modified by the addition of TiO₂ particles in the electrolyte, as shown by scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) methods, respectively. The TiO₂ content also significantly affected the mechanical and electrochemical properties of the Pd-Ni/TiO₂ composite coatings. The microhardness of the Pd-Ni/TiO₂ composite coatings can be enhanced by increasing the TiO₂ content in the coatings. With the addition of 5 g L⁻¹ TiO₂ particles to the electrolyte, the deposited Pd-Ni/TiO₂ composite coating presented a remarkably increased corrosion resistance when exposed to a sulfuric acid solution at 60 °C compared with that of the Pd-Ni alloy coating. Nevertheless, the further addition of TiO₂ particles into the electrolytic bath did not further improve the corrosion resistance of the composite coating. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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10 pages, 5517 KiB

Open AccessArticle

Microstructure Evolution of a Magnesium Phosphate Protective Layer on Concrete Structures in a Sulfate Environment

by Jun Li, Yongsheng Ji, Guodong Huang and Linglei Zhang

Coatings 2018, 8(4), 140; https://doi.org/10.3390/coatings8040140 - 14 Apr 2018

Cited by 10 | Viewed by 4679

Abstract

This study investigates the resistance of an uncoated magnesium phosphate cement (MPC) protective layer to sulfate attacks through changes in its compressive strength and appearance. X-ray Diffraction (XRD) and scanning electron microscopy (SEM) microanalyses are conducted on the MPC layer concrete both before and after etching, where changes in the microstructure of the magnesium phosphate protective layer are analyzed during the corrosion process. In addition, this study also explores the intrinsic mechanisms of the MPC protective layer in terms of the resistance of concrete to sulfate. The results showed that the erosion resistance of the concrete to sulfate can be dramatically improved by the MPC protective layer. The structure and composition of the MPC protective layer are different in the sulfate erosion environment compared with those exposed to other environments: the protective layer is more closely bonded to the concrete and has a more compact structure. Therefore, the MPC protective layer is verified to have a significant protective effect on concrete against sulfate corrosion. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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10 pages, 9182 KiB

Open AccessArticle

Realization of Graphene on the Surface of Electroless Ni–P Coating for Short-Term Corrosion Prevention

by Qin-Ying Wang, Jing Yu, Jiao Xu, Hao-Ming Fang, Shuang Liu, Yi-Rong Tang, Yu-Chen Xi and Shu-Lin Bai

Coatings 2018, 8(4), 130; https://doi.org/10.3390/coatings8040130 - 04 Apr 2018

Cited by 7 | Viewed by 4790

Abstract

Graphene was first fabricated on the surface of an electroless Ni–P coating/carbon steel (Ni–P–G) to improve its corrosion resistance. Meanwhile, an electroless Ni–P coating (Ni–P) was heated (Ni–P–H) under the same condition as Ni–P–G for comparison. The morphological results showed that a wavy multilayer graphene was formed on the surface of Ni–P–G. The layer number of the graphene film was 5–10 according to the analysis of Raman spectra and observation by a high-resolution transmission electron microscope. The I_D/I_G ratio calculated from the Raman spectrum revealed that the graphene growing at the grain of Ni–P–H had larger grain size than that growing at the grain boundary. The electrochemical results showed a higher R_p, a lower CPE_dl, and a lower corrosion rate of Ni–P–G than Q235 steel, Ni–P, and Ni–P–H, indicating a higher corrosion resistance. In addition, the surface potential map achieved by a scanning Kelvin probe presented a more positive surface potential of Ni–P–G than Ni–P with the difference being around 375–750 mV, demonstrating a lower corrosion tendency of Ni–P–G. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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15 pages, 59229 KiB

Open AccessArticle

Comparative Study of the Corrosion Resistance of Air-Plasma-Sprayed Ca₂SiO₄ and Al₂O₃ Coatings in Salt Water

by Yuan Xiao, Fang Shao, Yin Zhuang, Jinxing Ni, Huayu Zhao and Shunyan Tao

Coatings 2018, 8(4), 116; https://doi.org/10.3390/coatings8040116 - 22 Mar 2018

Cited by 7 | Viewed by 4528

Abstract

In this study, Ca₂SiO₄ coating was sprayed on stainless steel substrate and the corrosion resistance of the as-sprayed coating was studied in salt water. At the same time, Al₂O₃ coatings were produced by air-plasma-sprayed technology as comparison. Immersion test was carried out to evaluate the protection performance of coatings. Potentiodynamic polarization curves and electrochemical impedance spectroscopy (EIS) plots were also analyzed. The results indicated that Ca₂SiO₄ coatings showed a better protection performance than Al₂O₃ coatings. During the immersion, various calcium carbonate crystals appeared on the surface of Ca₂SiO₄ coatings. Ca(OH)₂ was released from Ca₂SiO₄ coatings into NaCl aqueous solution, increasing the alkalinity, which is in favor of the formation of passivation film, and thus improves the corrosion resistance. Ca₂SiO₄ coatings became denser after immersion due to the fact that the pores and micro cracks were filled with hydration products i.e., hydrated calcium silicate (C–S–H) gel. On the contrary, the microstructure of Al₂O₃ coatings became loose and obvious rusty spots were observed on the surface after the immersion test. Full article

(This article belongs to the Special Issue Advanced Coatings for Corrosion Protection in Extreme Environments)

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